CN102084517A - Battery system - Google Patents

Abstract

A high voltage connector (36) for a battery system (20) includes a body (100) having a first portion (114) and a second portion (116). The first portion (114) of the body (100) is located internal to a battery system housing and configured to receive at least one contact from the battery system (20). The second portion (116) is located external to the battery system housing and is configured to receive at least one contact from a vehicle. At least one connecting member (106) is coupled to the body (100). The connecting member (106) is configured to conductively connect the contact of the battery system (20) to the contact of the vehicle.

Description

Battery system

CROSS-REFERENCE TO RELATED PATENT

The application requires the priority and the interests of following patent application: the 61/053rd, No. 474 U.S. Provisional Patent Application that on May 15th, 2008 submitted to; The 61/055th, No. 407 U.S. Provisional Patent Application that on May 22nd, 2008 submitted to; The 61/055th, No. 896 United States Patent (USP) provisional application that on May 23rd, 2008 submitted to; The 61/080th, No. 645 United States Patent (USP) provisional application that on July 14th, 2008 submitted to; And the 61/085th, No. 787 United States Patent (USP) provisional application of submission on August 1st, 2008.

The whole disclosure of following patent application is incorporated among the application with way of reference: the 61/053rd, No. 474 U.S. Provisional Patent Application that on May 15th, 2008 submitted to; The 61/055th, No. 407 U.S. Provisional Patent Application that on May 22nd, 2008 submitted to; The 61/055th, No. 896 United States Patent (USP) provisional application that on May 23rd, 2008 submitted to; The 61/080th, No. 645 United States Patent (USP) provisional application that on July 14th, 2008 submitted to; And the 61/085th, No. 787 United States Patent (USP) provisional application of submission on August 1st, 2008.

Technical field

The present invention relates in general to battery and battery system field.More particularly, the present invention relates to and in vehicle is used, use to think that vehicle provides the battery and the battery system of at least a portion power.

Background technology

Compare with the more traditional petrol power vehicle that uses internal combustion engine, electrification as its power part or all vehicle (for example, motor vehicle (EV), hybrid electric vehicle (HEV), plug-in hybrid electric vehicle (PHEV) etc. are referred to as " motor vehicle ") many advantages can be provided.For instance, compare with the vehicle that uses internal combustion engine, motor vehicle can produce the less emission of not expecting and can represent higher fuel efficiency (and, in some cases, this vehicle can need not to use gasoline fully, such as in the PHEV of some types).

The motor vehicle technology continues to develop, and therefore need provide improved power supply (for example battery system or module) for these vehicles.For instance, expectation increases and these vehicles to be advanced and need not distance to battery recharge.Also expectation improves the performance of these batteries and reduces the cost relevant with battery system.

An improvement aspect that continues progress is the battery chemistries field.Previous motor vehicle system adopts nickel metal hydride (NiMH) battery as the promotion source.As time passes, different additives and modification have been improved performance, reliability and the effectiveness of NiMH battery.

Recently, manufacturer has begun to develop the lithium ion battery that can be used in the motor vehicle.Use lithium ion battery to use and have some associated advantages as vehicle.For example, lithium ion battery has higher charge density and specific power.In other words, in the electric charge that can store same amount, the comparable NiMH battery of lithium ion battery is littler, this can save weight in the motor vehicle and space (perhaps, optionally, this feature can allow manufacturer to provide more substantial power for vehicle, and can not increase the space that vehicle weight or battery system occupy).

Common known lithium ion battery is different with the performance or the working method of NiMH battery, and can present with the NiHM battery technology in different design and engineering problem (or challenge).For example, lithium ion battery aspect battery temperature than the suitable easier variation of NiMH battery, but thereby the temperature that using system is regulated lithium ion battery in the vehicle operating process.The manufacturing of lithium ion battery also presents the distinctive problem of this battery chemistries, and is developing new method and system solves these problems.

Summary of the invention

Expectation provides a kind of improvement battery module and/or system that is used for motor vehicle, and it solves the one or more problems relevant with NiMH that is used for this vehicle and/or lithium-ion battery systems.Also expectation provides a kind of battery module and/or system, and it comprises reads after the content disclosed herein conspicuous any one or a plurality of favorable characteristics.

According to an exemplary embodiment, a kind of high-tension connector that is used for battery system comprises the body with first and second portion.The first of body is positioned at the battery system enclosure interior and is configured to receive at least one contact (contact pin) from battery system.Second portion is positioned at the battery system outside and is configured to receive at least one contact from vehicle.At least one connecting elements couples

(connection) is to body.Connecting elements is configured to the contact conduction of battery system is connected to the contact of vehicle.

According to another exemplary embodiment, a kind of fuse (fuse) support that is used for battery system comprises the housing that is configured to keep fuse.Housing comprises at least one groove, and described at least one groove is configured to keep first end of securing member, so that groove limits the rotation of securing member basically.Securing member is configured to fuse is fixed in the housing.

According to another exemplary embodiment, a kind of method that buss-bar set is filled to battery module comprises provides a plurality of electrochemical cell that are arranged in battery module.In the battery unit each has the terminal that extends from its end.At least a portion of battery unit has the terminal that extends from first side of battery module, and at least a portion of battery unit has the terminal that extends from second side of battery module.This method also comprises provides the pallet that is configured to receive a plurality of busbars, and described pallet has the cover cap that is arranged on open position.This method further comprises a plurality of busbars is fixed on the pallet.This method also comprises location tray, so that the aperture in a plurality of busbar is aimed at the terminal of the battery unit at the first side place that is arranged on battery module, therefore described terminal can be coupled to all busbars in the pallet basically simultaneously.This method also comprises terminal is coupled to described a plurality of busbar.This method also comprises the cover cap of closing pallet.This method also comprises the terminal of battery unit that (a plurality of) independent busbar is coupled to second side of battery module, and its outside from battery module begins and proceed to the inside of battery module.This method also comprises along with independent busbar is coupled to battery module, provides the busbar cover cap on each independent busbar of second side of battery module.

Description of drawings

Fig. 1 is the perspective view that comprises the vehicle of battery module according to an exemplary embodiment.

Fig. 2 is that the perspective of the vehicle that provides with hybrid electric vehicle (HEV) form according to an exemplary embodiment partly cuts schematic diagram.

Fig. 3 is the decomposition diagram according to the battery system of an exemplary embodiment.

Fig. 4 is the decomposition diagram according to the battery pack of an exemplary embodiment, assembly or module.

Fig. 5 is the decomposition diagram that the busbar that is coupled to battery module shown in Figure 4 is shown according to an exemplary embodiment.

Fig. 5 A is the schematic diagram that passes the conductive path of battery module shown in Figure 4 according to an exemplary embodiment.

Fig. 6 is the perspective view that is used for the busbar assembly of battery module shown in Figure 5 according to an exemplary embodiment.

Fig. 7 is the upward view of busbar assembly shown in Figure 6.

Fig. 8 is the cross-sectional view along the busbar assembly of the intercepting of the line 8-8 among Fig. 7.

Fig. 9 is the decomposition diagram of busbar assembly shown in Figure 6.

Figure 10 is the perspective view that is used for the busbar bearing part of battery module shown in Figure 5 according to an exemplary embodiment.

Figure 11 is the part decomposition diagram of busbar bearing part shown in Figure 10.

Figure 12 is the vertical view of busbar bearing part shown in Figure 10.

Figure 13 is the flow chart that buss-bar set is filled to the method for battery module according to an exemplary embodiment.

Figure 14 is included in the perspective view of the battery switching units in the battery system shown in Figure 3.

Figure 15 is the exploded view perspective view that is included in the fuse holder assembly in the battery switching units shown in Figure 14 according to an exemplary embodiment.

Figure 16 is the perspective view of fuse holder assembly shown in Figure 15.

Figure 17 is the vertical view of fuse holder assembly shown in Figure 15.

Figure 18 is the cross-sectional view along the fuse holder assembly of Figure 17 center line 18-18 intercepting.

Figure 19 is the part decomposition diagram that comprises the battery switching units of high pressure (HV) connector according to an exemplary embodiment.

Figure 20 is the perspective view according to the high-tension connector of another exemplary embodiment.

Figure 21 is the part decomposition diagram of high-tension connector shown in Figure 20.

Figure 22 is the perspective view of high-tension connector shown in Figure 20.

Figure 22 A is the part decomposition diagram of high-tension connector shown in Figure 22.

Figure 22 B is the exploded view of high-tension connector shown in Figure 22.

Figure 23 is the perspective view according to the high-tension connector of another exemplary embodiment.

Figure 23 A is the part exploded view of high-tension connector shown in Figure 23.

Figure 24 is another perspective view of high-tension connector shown in Figure 20.

Figure 25 is the perspective view according to the following body of the high-tension connector shown in Figure 24 of another exemplary embodiment.

Figure 26 is the cross-sectional view along the high-tension connector shown in Figure 24 of the intercepting of the line 26-26 among Figure 24.

Figure 27 is the perspective view of the cover cap of high-tension connector shown in Figure 20.

Figure 28 is the part exploded view that comprises the high-tension connector shown in Figure 22 of interlocking part according to an exemplary embodiment.

Figure 29 is according to the interlocking part of another exemplary embodiment and the perspective view of connector.

Figure 30 is the interlocking part shown in Figure 29 and the exploded view of connector.

Embodiment

Fig. 1 is that this motor vehicle has thebattery system 20 that is used for providing tovehicle 10 all or part of power with the perspective view of thevehicle 10 shown in motor vehicle (for example car) form.Thisvehicle 10 can be the other types vehicle (being generically and collectively referred to as " motor vehicle ") that motor vehicle (EV), hybrid electric vehicle (HEV), plug-in hybrid electric vehicle (PHEV) or electrification promote or drive.

Though vehicle is shown in Figure 1 is car, and type of vehicle can change according to other exemplary embodiments, and all these embodiment all should fall in the scope of content disclosed herein.For example,vehicle 10 can be that truck, bus, industrial vehicle, motorcycle, amusement tourist vehicle, ship maybe can be benefited from electrification all or part of any other type of vehicle as its motive force.

Be arranged in luggage of vehicle or afterbody thoughbattery system 20 is shown as in Fig. 1, according to other exemplary embodiments, the position ofbattery system 20 can change.For example, the position and many other of other assemblies (for example battery management system, floss hole or cooling device etc.) that can use based on the free space in the vehicle, the required weight balancing of vehicle, withbattery system 20 consider to select the position ofbattery systems 20.

The part that thevehicle 10 that provides with the HEV form according to exemplary embodiment is provided Fig. 2 cuts schematicdiagram.Battery system 20 is arranged to towards the contiguous fuel tank 12 (battery system 20 can be arranged to be close tofuel tank 12, maybe can be arranged in the independent compartment (for example luggage case) invehicle 10 afterbodys, maybe can be arranged on other positions in the vehicle 10) of the afterbody of vehicle 10.Whenvehicle 10 utilizes petrol power to promotevehicle 10, also provide internal combustion engine 14.Motor 16, distributing means forpower supply 17 andgenerator 18 also provide as the part of driver for vehicle.Thisvehicle 10 can be only bybattery system 20, only both provide power or driving byengine 14 or bybattery system 20 and engine 14.It should be noted that according to other exemplary embodiments, can use the vehicle of other types or vehicle electrical system is used the structure of other types, and should not think that the schematic elaboration among Fig. 2 limits the scope of the subject matter of description in this application.

According to different exemplary embodiments, the type of the size ofbattery system 20, shape and position andvehicle 10, vehicle technology type (for example EV, HEV, PHEV etc.) and battery chemistries etc. can be different with the situation that illustrates here or describe.

With reference to Fig. 3, show the exploded view ofbattery system 20 according to exemplaryembodiment.Battery system 20 comprises a plurality of electrochemical cell or battery 40 (for example lithium ionic cell unit, nickel metal hydride battery unit, lithium polymer battery unit etc., or the known now or other types electrochemical cell of exploitation in the future).According to exemplary embodiment,electrochemical cell 40 is configured for the general cylindrical nickel metal hydride battery unit of stored charge.According to other exemplary embodiments,battery unit 40 can have other physiques (for example oval, prismatic or polygon etc.).The capacity ofbattery unit 40, size, design and other features also can be different from situation about illustrating here according to other exemplary embodiments.

The parts ofbattery system 20 are contained in insulator seal piece installing or the container, and described packaging part or container are shown as in Fig. 3 bycover cap 22,substrate 24 andend cap 26 andform.Cover cap 22,substrate 24 andend cap 26 are formed by polymer or other non-conducting materials, and can couple (connection) by the different institutions that comprises threaded fastener, integrally formed latch piece or fastener member, pin etc. together.As described in greater detail below, the break function ofbattery system 20 can be built incover cap 22,substrate 24 and/or theend cap 26.

According to exemplary embodiment,battery system 20 comprisesbattery module 30, its encapsulation or holdelectrochemical cell 40, other features thatelectrochemical cell 40 was interconnected and/or was connected to the miscellaneous part of vehicle electrical system and management or regulateselectrochemical cell 40 and battery system 20.Battery system 20 can comprise to be responsible for the electrical property of system is monitored and the thermal behavior of control, management system, held and/or transmits the otherwise feature of effluent (for example gas that can discharge from battery unit) andbattery system 20.

Though the exemplary embodiment ofbattery system 20 has been shown among Fig. 3, has should be understood thatbattery system 20 is not limited to read any customized configuration that will understand after the content disclosed herein.For example, though thebattery system 20 shown in Fig. 3 is illustrated as thebattery unit 40 with horizontal orientation, it by row or rod is configured to two-layer or two groups, however, it should be understood that battery module can have many not isostructures by the parallel frame frame member.For example, battery unit also can vertically be arranged, form the plurality of separate group substantially or dispose with other structures.In addition, can use the battery unit of different numbers and type (for example nickel metal hydride etc.).

As shown in Figure 4, according to exemplary embodiment,battery module 30 comprises two layers 42,44 and a plurality ofpallet 46 of battery unit 40.In the ground floor 42 and the second layer 44 each comprises multirow battery unit 40.Battery unit 40 in every row couples end to end withadjacent cell 40, thereby forms bar or rod 43.Battery unit rod 43 is contained in thegroove 48 that is formed in the pallet 46.Pallet 46 also can comprise pressurizating ventilation space or other features, with provide tobattery unit 40 cooling air or will from any emission gases of fail battery unit isolate or guiding away from vehicle 10.Pallet 46 is made by polymeric material or other suitable materials (for example electrical insulating material).The battery unit feature at interval that is used to provide away from tray surface and/or adjacent cell also can be providedpallet 46.

Though be to have theelectrochemical cell 40 of given number shown in Fig. 3 and 4, but, should note, according to other exemplary embodiments,battery system 20 can according in the multiple consideration any (for example, the battery system required drive, the free space that battery system must assemble etc.) and have theelectrochemical cell 40 of different numbers and/or configuration.

Be arranged tobattery unit 40 electric coupling together (electric coupling) in circuit with a plurality of electric connectors (for example, shown in Fig. 5-12) that busbar 70 forms are provided with.Fig. 5 shows an exemplary embodiment, wherein a side ofbattery module 30 comprises bus-bar container or bearingpart 60, it has the busbar of first group of approximate horizontal orientation, so that theadjacent cell rod 43 onbattery unit rod 43 and the identical layer is coupled, and the opposition side of battery unit assembly comprises a plurality ofbusbar assemblies 50, it has second group of roughly vertical busbar, so that the battery unit on the ground floor 42rod 43 is coupled with the vertical battery unit rod of aiming at 43 on the second layer 44.In a further exemplary embodiment, second group of busbar can be contained in the second busbar bearing part or thecontainer.Busbar assembly 50 is coupled inbattery unit 40 in thebattery module 30 withbusbar bearing part 60, and to form continuous conduction path 49, one of them example is shown in Fig. 5 A.

In Fig. 6-9, illustrate in greater detail anexemplary busbar assembly 50 that comprisesbusbar 70 and lid 52.Busbar 70 is thatadjacent cell 40 is coupled in togetherhardware conductively.Busbar 70 comprises aperture orhole 71, can pass described aperture orhole 71 such as the securingmember 58 of screw,busbar 70 is coupled to the terminal 41 of battery unit 40.According to exemplary embodiment (for example, shown in Fig. 6-9), be installed on the side ofbattery module 30 when allbusbars 70 after, replace using single lid to cover allbusbars 70, eachbusbar assembly 50 comprises and covers 52 that being dimensioned to of describedlid 52 coverssingle busbar 70 and can be coupled tobusbar 70 immediately after it is coupled tobattery unit 40.

Lid 52 is formed by the electrically non-conductive material such as polymeric material (for example polypropylene, polyethylene etc.), and has openend 53, with slip onbusbar 70 and securingmember 58 or slipover.Lid 52 has roughly U-shaped or Horseshoe cross section, and it has theouter wall 56 around the side of busbar 70.From theouter wall 56 inside outstanding lips or the back side contacts ofedge 55 andbusbar 70, remain on thebusbar 70 to help to cover 52.Rib 54 extends from the roof of lid.According to exemplary embodiment,rib 54 andlid 52 monolithic moldings.Fromrib 54 tolip 55 distance less than from the top of thehead 59 ofscrew 58 to the distance of the bottom ofbusbar 70, therefore whenlid 52 slides onbusbar 70 and the securingmember 58, form interference (interference) cooperation.Interference fit has reduced by the 52 respond vibration power of covering and the probability that shakes up frombusbar 70.

Illustrate in greater detail an exemplarybusbar bearing part 60 among Figure 10-12.Busbar bearing part 60 is formed in the sealing packaging part and keeps a plurality ofbusbars 70 and a plurality of sensor terminal 72.Busbar bearing part 60 can be assembled with battery module 30 (as shown in Figure 5), withbattery unit 40 electric coupling simultaneously together, prevents from simultaneously to contact with the electric parts ofbattery system 20 are unexpected.According to an exemplary embodiment,busbar bearing part 60 forms single body by the non-conductive polymer such as polypropylene, polyethylene, high hot ABS or any other suitable polymeric material.Busbar bearingpart 60 can be by injection moulding or other suitable technology manufacturings.

According to an exemplary embodiment, bearingpart 60 comprise main compartment orpallet 62 and withpallet 62 integrally formed lids 64.Lid 64 is gone up at integrally formed hinges 63 (for example forming by the thickness area that reduces in the polymeric material) and is pivoted, and utilizes one or more fastening features, is fastened on off-position as theconnector 65 that is clasped among Figure 10-12.

According to an exemplary embodiment,lid 64 can be hinged or be coupled to pallet.For example,lid 64 can be by the mode beyond the hinges (for example by internal mold weaving thing hinge, the independent hinge that is formed by polymer, metal or other suitable materials etc.) with respect topallet 62 pivots.In another exemplary embodiment,lid 64 can be set to independent cover cap.Say it for example,lid 64 can be coupled topallet 62 by the connection that is clasped, glossal canal connection or securing member, hook etc.

Busbar 70 is the hardwares that coupleadjacent cell 40 conductively.Eachbusbar 70 compriseshole 71, can pass theseholes 71 such as the securing member (not shown in Figure 10-12) of screw or bolt,busbar 70 is coupled to the terminal 41 (terminal 41 has the internal thread that is used to receive securing member) of battery unit 40.Though according to another exemplary embodiment, thebusbar 70 shown in Fig. 6-12 is roughly the same on shape and size,, the busbar that bearingpart 60 receives can be different with the busbar ofindependent busbar assembly 50 on size and dimension.In addition, each inassembly 50 and/or the bearingpart 60 for example can comprise the busbar with multiple shape and/or size, passes the different conductive paths ofbattery module 30 or compensatesdifform battery module 30 with formation.

Opening 66 in the pallet 62 (for example, allows battery unit terminal 41 to passpallet 62, to be coupled tobusbar 70 as shown in figure 11).Pallet 62 comprises and is used for inside separator orwall 67 that busbar 70 is isolated from each other, thereby makes them can not touch and form short circuit.Either side atconductive path 59 is provided with terminal connector or encircles 68, to receive the connector thatbattery module 30 is coupled to vehicle electrical system.The opening thatterminal connector 68 passes in the sidewall extends from the end opposite of bearingpart 60.

Busbar bearing part 60 further is configured to hold a plurality of sensor terminal 72.Sensor terminal 72 (for example is coupled to bolt or other securing members in the different piece that the one end is connected to the conductive path 49 ofbattery module 30, above-mentioned bolt or other securing members are coupled tobusbar 70 terminal 41 of battery unit 40), and be connected to the battery management system (BMS) 34 of battery switching units (BDU) 32 at the otherend.Sensor terminal 72 is provided, with at the different aspect (for example temperature, electric current, voltage etc.) along the difference place of conductive path 49 monitoring battery unit 40.Distribution trough 69 is arranged between two row'sbusbars 70, to collect sensor conductor (not shown) such as (for example hold, maintenance).Collecting sensor lead (for example collecting in the standardization wire harness) has been simplified the encapsulation and the assembling ofbattery module 30, and allows more easily near busbar 70.Thoughgroove 69 is shown as the center that roughly is positioned at bearingpart 60, according to other exemplary embodiments, groove 69 also can be arranged on other positions on the bearingpart 60, for example along a side of bearingpart 60 or be positioned on the outer surface of bearingpart 60.

Battery module 30 among Fig. 5 roughly is assembled in thepallet 46 by the battery unit 40 (for example the battery unit rod 43) of the first one-tenthrow arrangement.Pallet 46 is stacked into the feasible terminal 41 that only exposes the end of each row's battery unit 40.According to an exemplary embodiment,busbar bearing part 60 comprises and is used forbusbar 70 andsensor terminal 72 are remained on feature (feature for example is clasped) in the busbar bearing part 60.By providingfeature keeping busbar 70 andsensor terminal 72,busbar 70 andsensor terminal 72 are assembled in thebusbar bearing part 60 before can be on being assembled tobattery module 30 in advance.Pre-assembledbusbar bearing part 60 can then be coupled tobattery module 30 in quick and simple mode.

Referring now to Figure 13, show the flow chart of the method for describing assemblingbusbar assembly 50,busbar bearing part 60 andbattery module 30 according to an exemplary embodiment.In thefirst step 150, open busbar bearing part 60 (that is,lid 64 is opened, and exposes the inside ofmain compartment 62).Insecond step 152,busbar 70 inserts in the bearingpart 60 and can keep in position by hasp feature or interference fit.In the3rd step 154, pre-assembledbusbar bearing part 60 is positioned on the battery unit terminal 41, contacts between the terminal 41 of allbusbars 70 in bearingpart 60 and a side ofbattery module 30 simultaneously basically.In the4th step 156,busbar 70 is coupled on the terminal 41 by bolt or other securing members.In the5th step 158, thelid 64 of bearingpart 60 is closed, thereby the personnel that will remain onbusbar 70 and assembledbattery module 30 in the bearingpart 60 effectively isolate.

After thelid 64 that busbar 70 inbusbar bearing part 60 is coupled to the terminal 41 of first side ofbattery module 30 and bearingpart 60 was closed, in the6th step 160,independent busbar 70 then was coupled to the terminal 41 ofbattery unit 40 of second side of battery module 30.In one exemplary embodiment,independent busbar 70 is coupled to second side ofbattery module 30, and its outside frombattery module 30 begins and proceed to the inside or the center of battery module 30.By this assembling process, when last or center busbar 70a were coupled to the battery terminal 41 of second side ofbattery module 30, the complete conductive path 49 ofbattery module 30 was just finished or is connected.Center busbar 70a last connection in assembling process " cut apart the conductive path 49 ofbattery module 30 " into two basically, thereby stayed two low pressure memory banks of battery unit 40.In the7th step 162, center busbar 70a is connected to the battery unit terminal 41 of second side ofbattery module 30 by automated procedure or by the personnel that worn protector, links together with the two halves with the conductive path 49 of battery module 30.When center busbar 70a was coupled tobattery module 30,battery module 30 just was in effectively or " high pressure " state.

According to another exemplary embodiment, can not useindependent busbar 70, and utilize the second busbar bearing part, so the both sides ofbattery module 30 all utilize the busbar bearing part in second side ofbattery module 30.

With reference to Figure 14,, show the battery switching units (BDU) 32 that is used forbattery system 20 according to anexemplary embodiment.BDU 32 comprises the electronic control unit that is depicted as battery management system (BMS) 34, electric current, voltage and/or the temperature of thebattery unit 40 in this battery management system regulating cellmodule 30.Splitter 38 is electrically coupled toBMS 34, and is electrically coupled to the electric system of high-tension connector 36 andvehicle 10 by fuse component 74.Fuse component 74 comprises thefuse 80 of isolating and insulating byfuse holder 82 and BMS support 35.Fuse component 74 utilizesfirst busbar 76 at one end to be coupled to fusecomponent 74, and utilizessecond busbar 78 to be coupled tocontactor 92.

Figure 15-18 illustrates in greaterdetail fuse holder 82 and associated components according to an exemplaryembodiment.Fuse holder 82 is the installation components that formed by the non-conducting material such as polymeric material (for example polypropylene, polyethylene etc.) or other suitable materials.Fuseholder 82 holds fuse 80, and describedfuse 80 comprises two ends 81 (for example flange, arm etc.) that contain porose or aperture.Be not multi-piece type parts or the parts that comprise customization threaded portion or anchor clamps, thefuse holder 82 shown in Figure 15-18 is simple relatively single component, and it comprises thegroove 83 that is used to keep such as the secure component of two common (can be purchased off the shelf) ofhex bolts 84.

Thehead 85 ofbolt 84 remains in thegroove 83 offuse holder 82, so that they can not rotate (or can not rotate basically).According to an exemplary embodiment, groove 83 andbolt head 85 have the gap of about 1/10mm at the either side ofbolt head 85, and have the gap of about 1/2mm inbolt head 85 above and belows.Theend 81 ofsleeve 86 andfuse 80 is assemblied on the bolt 84.Nut 88 is threaded io on thebolt 84 and is fastening, so thatfuse 80 is coupled to fuse holder 82.Because thehead 85 ofbolt 84 is maintained fixed, so whennut 88 was fastening,bolt 84 can not rotate.Sleeve 86 provides metal body betweenbolt head 85 andnut 88, therefore fastening so thatfuse 80 is fixing in position the time whennut 88, exists metal-metal to contact betweensleeve 86,fuse 80,busbar 76,68 and nut 88.This metal-metal contact is guaranteed the plastic components that compresses between metal parts, to guarantee strong and reliable connection.

Thebolt 84 that can be purchased off the shelf by use is fastened to fuse 80fuse holder 82 and by using single-piece fuse holder 82, can reduces the manufacturing cost of battery system 20.In addition, whensleeve 86 was assemblied on thebolt 84,groove 83 further keptbolt 84 in position, so fuseholder 82 can move around (for example waiting to be coupled to BMS support 35) and can not make thatbolt 84 comes off.

Return Figure 14,BUD 32 further comprisesfirst contactor 90,second contactor 92 and is depicted as the relay of pre-charge-relay 94.Contactor 90 and 92 is automatically controlled (by BMS 34) switches, and described switch is the part of the high-tension circuit of battery system 20.Contactor 90 and 92 is normal open switch, when they during fromBMS 34 received signals, described switch closure is so that allow electric current to pass them and finish high-tension circuit.First contactor 90 is arranged on the side of the positive electrode of high-tension circuit, andsecond contactor 92 is arranged on the negative side of high-tension circuit.Pre-charge-relay 94 operation, withcontactor 90 and 92 closed and finish circuit before to the capacitor charging ofbattery system 20.

Referring now to Figure 19, according to an exemplary embodiment,BDU 32 comprises high-tension connector 36.High-tension connector 36 is electrically connected toBMS 34 by fuse component 74.36 electric systems thatbattery system 20 are connected tovehicle 10 of high-tension connector.Electric system in high-tension connector 36 bridge battery systems 20 (for example be contained incover cap 22 or for example in the body panels of other shown in Fig. 3) and the outer electric system (for example,outside cover cap 22 or other body panels) of battery system.According to exemplary embodiment shown in Figure 19, theend cap 26 that high-tension connector 36 passes on the side ofbattery system 20 stretches out battery system 20.According to other exemplary embodiments, high-tension connector 36 can be arranged on other positions such as the top ofbattery system 20.

Referring now to Figure 20-22 and 24-28, show high-tension connector 36 according to another exemplary embodiment.High-tension connector 36 comprisesbody 100 with top 102 andlower part 104, be arranged on busbar betweenupper body part 102 and thelower body portion 104 or connectingelements 106 and securingmember 108, thecover cap 112 and the release mechanism 130 (such as the interlocking part) of the parts of partially enclosed atleast connector 36.

Thebody 100 of high-tension connector 36 comprises and is configured to the second portion 116 (being also referred to as exterior section) that stretches into the first 114 (being also referred to as interior section) ofbattery system 20 and stretch out battery system 20.Thecover cap 112 of high-tension connector 36 is configured to theexterior section 114 of partially enclosed at least body 100.Body 100 andcover cap 112 are by forming such as the polymer (for example polyethylene, polypropylene etc.) or the non-conducting material of other suitable materials.Make itscover cap 22 both sides extend by thebody 100 that forms high-tension connector 36 atbattery system 20, no longer need be such as the hardware and the additional number of assembling steps that is used for being connected body of bolt atcover cap 22 either sides.

Theupper body 102 of high-tension connector 36 comprises thewall 118 of separatinginterior section 116 and exterior section 114.According to an exemplary embodiment,interior section 116 andexterior section 114 form single body.Oninterior section 116 andexterior section 114, form aperture (for example opening, hole, gap etc.).The aperture is aimed at socket 120 (for example hollow, dimple, cavity etc.).Socket 120 receives the busbar 110 (for example contact, conductive member etc.) frombattery system 20 oninterior section 116, and externallypart 114 receives contact from the electric system ofvehicle.Socket 120 is surrounded by relative or quite high wall 122 (for example feature, separator, separator etc.) at least in part, contacts to help prevent the accident between the adjacent contact, thereby reduces short circuit probability.According to an exemplary embodiment,socket 120 comprises molded plus orminus symbol 124, with the polarity of indication contact to be received.According to other exemplary embodiments, can indicate (for example utilizing Printing Marks) or not indicate polarity.

Busbar onexterior section 114 and theinterior section 116 or other contacts (not shown) are coupled in by being arranged on the connecting elements 106 (for example busbar, conductive member etc.) ofupper body 102 between followingbody 104, thereby finish the circuit between vehicle electrical system and the battery system 20.Connecting elements 106 is coupled to from vehicle and from the busbar of battery system by threaded fastener, and above-mentioned securing member is for example for extending through thebolt 108 in the hole in the connectingelements 106 and being threaded in nut (not shown) on the bolt 108.According to other exemplary embodiments, connectingelements 106 can be coupled in together by other mechanisms that connect, sell connection, riveted joint or any other suitable mechanism such as blade.

Followingbody 104 is coupled toupper body 102 by the securing member such as screw (not shown).According to other exemplary embodiments,upper body 102 and followingbody 104 can be coupled in together, such as by the connection that is clasped.Connecting elements 106 and threadedfastener 108 are arranged betweenupper body 102 and the following body 104.Followingbody 10 comprises and is formed for receiving the sleeve of securingmember 108 or the lug boss of socket 105.According to an exemplary embodiment,sleeve 105 is hexagonal, to receive the head of securing member 108.According to another exemplary embodiment,sleeve 105 can have difformity (for example square).Sleeve 105 provides the anti-rotation feature, thereby when being coupled to connectingelements 106 from the contact of vehicle electrical system with from the contact ofbattery system 20, prevents thatbolt 108 fromrotating.Securing member 108 extends through opening and theexterior section 114 ofconnector 36 and the opening in the contact on theinterior section 116 in the connecting elements 106.Nut (not shown) is threaded io on the securingmember 108, thereby against the contact of the end opposite compression that is arranged at the connectingelements 106 in the high-tension connector 36 from vehicle and battery system.

Thecover cap 112 of high-tension connector 36 is theexterior section 114 ofenclosed body 100 basically, to reduce personnel or object and from the unexpected contact probability between the contact of vehicle electricalsystem.Cover cap 112 can further comprise the interlocking part 130 (for example member, contact, blade etc.) that disconnects battery system.When removingcover cap 112, interlockingpart 130 is configured to send signals toBDU 32, interrupting the conductive path ofbattery system 20, thereby the electric current high-tension connector 36 of will can not flowing through.

Referring now to Figure 23 and 23A, show high-tension connector 36 according to anotherexemplary embodiment.Body 100 andcover cap 112 comprise and stretching out and away from the extension 125,127 of high-tension connector 36.The structural rigidity that has improvedbody extension 126 with the member or the element of projection orrib 126 form settings.The favorable characteristics that extension 125,127 is set frombody 100 andcover cap 112 is, is coupled at the exposure current-carrying part of the outside of high-tension connector 36 and battery cables between the point at high-tension connector 36 places to have additional distance.In this way, extension 125,127 is used for providing cover cap or guard shield at least a portion of the battery cables that is coupled to high-tension connector 36 (not shown).

Return Figure 20 and 21,cover cap 112 can be configured to hide at least one of the securingmember 128 be used for fastening battery system housing (forexample end cap 26 being fastened to covercap 22).Must removecover cap 112 with the approaching securing member of hiding 128.Remove cover cap 112 will disconnecting interlockingpart 130, thereby causeBDU 32 to disconnectbattery systems 20 near securing member 128.In this way, before thecover cap 22 ofremovable battery system 20, turn-off battery system 20.When highpressure cover cap 112 was put back on the position on the high-tension connector 36, interlockingpart 130 was once more with 132 contacts of interlocking connector or be connected, to finish circuit.When circuit was finished,BDU 32 reconnectedbattery system 20, the high-tension connector 36 thereby the permission electric current is flowed through.

Referring now to Figure 22 B, interlockingconnector 132 is arranged betweenupper body 102 and thefollowing body 104, and it has fourpin connectors 134 that extend throughupper body 102 in the outside 114 of high-tension connector 36 and twopin connectors 136 that extend throughupper body 102 in theinboard 116 of high-tension connector 36.Four pin connectors, 134 engagement interlocking parts 130,130 of interlocking parts are coupled to high pressure cover cap 112.Twopin connectors 136 are coupled toBDU 32 by data cable (not shown).

Interlockingpart 130 and interlockingconnector 132 can diverse location and orientation be arranged on thebattery system 20, so that break function to be provided when removing cover cap 22.As shown in figure 19, interlockingconnector 132 can be coupled to batterysystem cover cap 22, and interlockingpart 130 is coupled to high pressure cover cap 112.Shown in Figure 20-28, interlockingconnector 132 can be coupled to high-tension connector 36, and interlockingpart 130 is coupled to high pressure cover cap 112.According to other exemplary embodiments, interlockingpart 130 and interlockingconnector 132 also can be coupled tobattery system 20, so that when exposingconnector 36 when removing highpressure cover cap 112, their disconnect.

Though according to other embodiment, interlockingpart 130 shown in Figure 19-28 is the connectors that can be purchased from the molex inc of Illinois Li Sier, but, interlockingpart 130 can be any suitable mechanism, this mechanism finishes circuit when highpressure cover cap 112 is positioned at suitable position, and whencover cap 112 removes open circuit.Say it for example, shown in Figure 29-30, interlockingpart 130 can be connected by blade type with interlockingconnector 132 and is engaged with eachother.Interlocking part 130 comprises contact or blade-section 140 and mounting portion 142.Blade 140 is included on the interlocking connector and two ledges ofcontact 144 engagements (for example extension etc.).According to other exemplary embodiments,blade 140 can have more or less jut (for example single jut is accessibly connected two contacts on the device).Contact 144 on the interlockingconnector 132 can be the spring type contact, and can be contained in the main body orhousing 146 of interlocking connector 132.Similar to the embodiment among Figure 19-28, interlockingpart 130 is coupled to highpressure cover cap 112, and interlockingconnector 132 is coupled to another parts such as batterysystem cover cap 22 or high-tension connector 36.

According to any the foregoing description, interlockingconnector 132 can be coupled tobattery system 20 or be coupled to high-tension connector 36 by the connection that is clasped.In other embodiments, interlockingconnector 132 can use the securing member such as screw or rivet to couple.Similarly, interlockingpart 130 can connect thecover cap 112 that is coupled to high-tension connector 36 by being clasped, and perhaps can use the securing member such as screw or rivet to couple.In another embodiment, interlockingpart 130 can be coupled to high-tension connector 36, and interlockingconnector 132 can be coupled to thecover cap 112 of high-tension connector 36.According to other exemplary embodiments, interlockingpart 130 can have another mechanism, connects or the connection of pin type such as the plug type.

Term used herein " approximately ", " pact ", " basically or roughly " and similar terms should possess the corresponding to extensive connotation of application of generally acknowledging and accepting with the theme those skilled in the art of disclosure here.That reads disclosure here it will be understood by those skilled in the art that these terms are intended to allow this paper is described and some features of request are described, and is not that scope with these features is limited to accurate number range provided herein.Correspondingly, these terms should be interpreted as, and indication this paper describes and the unsubstantiality of the theme of request or inessential modification or modification are considered as falling in the scope of the present invention that appended claim limits.

It should be noted that the term " exemplary " that is used to describe different embodiment herein be intended to indicate these embodiment be possible embodiment possible example, represent and/or illustrate (and this term be not used in these embodiment of expression are the very special or best examples of certainty).

Term used herein " couples ", " connection " etc. means two members be engaged with each other directly or indirectly (or linking to each other).This joint can be (for example permanent) fixed or movable (for example removable maybe can discharge).Two members and any additional intermediate member realization that this joint can form single body by two members or mutual integral body perhaps can realize by two members or two members and any other intermediate member of being attached to each other together.

The position of components that this paper quotes (for example " top ", " bottom ", " on ", D score etc.) only be used for the orientation of each element of description figure.The orientation that it should be noted that each element can be according to other exemplary embodiment and is different, and these variations all should be included in the content disclosed herein.

Especially the structure and the configuration that it should be noted that the battery system shown in the different exemplary embodiments only are exemplary.Though content disclosed herein is only described some embodiment in detail, but the those skilled in the art that read content disclosed herein will be readily appreciated that, under the situation of instruction that does not depart from theme described herein in fact and advantage, multiple modification all is possible (for example variation of each size of component, size, structure, shape and ratio, variations of parameter value, installation configuration, material use, color, orientation etc.).For instance, being depicted as integrally formed element can be made of a plurality of parts or element, and position of components can be put upside down or change, and the character of discrete elements or position or number can change or change.The order of any process or method step or order can or rearrange according to different embodiment variations.Under the situation that does not depart from the scope of the invention, he replaces, revises, changes and omits can and to be configured into the Xingqi to design, the operation condition of each exemplary embodiment.

Claims (20)

1. high-tension connector that is used for battery system comprises:

Body, it has first and second portion, the first of described body is positioned at the battery system enclosure interior and is configured to receive at least one contact from described battery system, and described second portion is positioned at described battery system outside and is configured to receive at least one contact from vehicle; And

At least one connecting elements, it is coupled to described body, and described connecting elements is configured to the contact conduction of described battery system is connected to the contact of described vehicle.

2. high-tension connector as claimed in claim 1 is characterized in that, further comprises first securing member of first end that is positioned at described connecting elements and second securing member that is positioned at second end of described connecting elements.

3. high-tension connector as claimed in claim 2 is characterized in that described body comprises socket, and described socket is configured to receive first end of described first securing member, so that described socket limits the rotation of described first securing member basically.

4. high-tension connector as claimed in claim 3 is characterized in that, described socket is at least one in the square and hexagon.

5. high-tension connector as claimed in claim 1, it is characterized in that, described body comprises feature, and described feature is configured to partly surround when contact when the contact of described battery system and described vehicle is coupled to described at least one connecting elements the contact of described battery system and the contact of described vehicle.

6. high-tension connector as claimed in claim 1 is characterized in that, further comprises second connecting elements, and wherein said first connecting elements is a positive contact, and described second connecting elements is a negative contact terminal.

7. high-tension connector as claimed in claim 1 is characterized in that, further comprises cover cap, and described cover cap is configured to seal basically the described second portion of described body, to reduce and the unexpected probability that contacts of the contact of described vehicle.

8. high-tension connector as claimed in claim 7 is characterized in that described cover cap comprises extension, so that the additional covering to the contact of described vehicle to be provided.

9. high-tension connector as claimed in claim 7 is characterized in that described body comprises first contact, and described cover cap comprises second contact, make thus when described cover cap when described body removes, described second contact breaks away from from described first contact.

10. high-tension connector as claimed in claim 7 is characterized in that, described cover cap is hidden the securing member that is used to keep the cover cap on the described battery system basically.

11. a fuse holder that is used for battery system comprises:

Be configured to keep the housing of fuse, described housing comprises at least one groove, described at least one groove is configured to keep first end of securing member, so that described groove limits the rotation of described securing member basically, described securing member is configured to described fuse is fixed in the described housing.

12. fuse holder as claimed in claim 11 is characterized in that, further comprises sleeve, described sleeve places on second end of described securing member, so that described securing member is remained on the described housing.

13. fuse holder as claimed in claim 11 is characterized in that, further is included in the fuse that is coupled to described securing member in the described housing.

14. one kind is filled to the method for battery module with buss-bar set, comprising:

The a plurality of electrochemical cell that are arranged in battery module are provided, in the described battery unit each has the terminal that extends from its end, at least a portion of described battery unit has the terminal that extends from first side of described battery module, and at least a portion of described battery unit has the terminal that extends from second side of described battery module;

The pallet that is configured to receive a plurality of busbars is provided, and described pallet has the cover cap that is arranged on open position;

A plurality of busbars are fixed on the described pallet;

Locate described pallet, so that the aperture in described a plurality of busbar is aimed at the terminal of the described battery unit at the described first side place that is arranged on described battery module, therefore described terminal can be coupled to all busbars in the described pallet basically simultaneously.

Described terminal is coupled to described a plurality of busbar;

Close the cover cap of described pallet;

Independent busbar is coupled to the terminal of described battery unit of described second side of described battery module, it begins and proceeds to described battery module inside from described cell module outer portion; And

Along with independent busbar is coupled to described battery module, on each described independent busbar of described second side of described battery module, provide the busbar cover cap.

15. method as claimed in claim 14 is characterized in that, last independent busbar that will be coupled to described battery module in described second side of described battery module is middle independent busbar.

16. method as claimed in claim 14 is characterized in that, described pallet has the feature that is clasped that is configured to receive described a plurality of busbars.

17. method as claimed in claim 14 is characterized in that, described busbar pallet comprises the distribution trough of the location placed in the middle that is configured to receive distribution.

18. method as claimed in claim 14, it is characterized in that, the described cover cap that is arranged on the described independent busbar of described second side of described battery module comprises rib, and described rib is configured to form interference fit with the securing member that is used for described independent busbar is coupled to described terminal.

19. method as claimed in claim 18 is characterized in that, described rib and described cover cap are whole to be formed.

20. method as claimed in claim 18 is characterized in that, described cover cap comprises internal recess and is formed on the described independent busbar and slides.

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